Service Manual

FLEXIBLE BATCH
BROILER

MODELS
FBB-EO-208
FBB-EC-208
FBB-EO-230
FBB-EC-230
FBB-EO-240
FBB-EC-240

Please read this manual completely before attempting

to install, operate or service this equipment

This document is prepared for trained Duke service technicians. It is not to be used by anyone not
properly qualified to perform these procedures.

This Service Manual is not all encompassing. If you have not been trained on servicing this product,
be sure to read the manual completely before attempting servicing. Be sure all necessary tools,
test equipment, and skills are available. Those procedures for which you do not have the proper
skills and test equipment must be performed only by a qualified Duke trained service technician.

This manual is Copyright © 2010 Duke Manufacturing Co. All rights reserved.
Reproduction without written permission is prohibited. Duke is a registered
trademark of the Duke Manufacturing Co.

Duke Manufacturing Co.

2305 N. Broadway
St. Louis, MO 63102
Phone: 314-231-1130
Toll Free: 1-800-735-3853
Fax: 314-231-5074
www.dukemfg.com

P/N 177769A
Service Manual for Flexible Batch Broiler Units
IMPORTANT WARNING AND SAFETY INFORMATION
THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL
ELECTRICAL EQUIPMENT, WHO SHOULD PERFORM THE INITIAL FIELD START-
UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL.
READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR
PERFORMING MAINTENANCE ON THE EQUIPMENT.
Failure to follow all the instruc-
tions in this manual can cause property damage,
injury or death.
Improper installation, adjust-
ment, alteration, service or maintenance can
cause property damage, injury or death.
Electrical connections should
be performed only by a certified professional.
Electrical and grounding con-
nections must comply with the applicable por-
tions of the National Electric Code and/or all
local electric codes. Failure to comply with this
procedure can cause property damage, injury or
death.
Before connecting the unit to
the electrical supply, verify that the electrical and
grounding connections comply with the appli-
cable portions of the National Electric Code and/
or other local electrical codes. Failure to comply
with this procedure can cause property damage,
injury or death.
Before connecting the unit to
the electrical supply, verify that the electrical
connection agrees with the specifications on the
data plate. Failure to comply with this procedure
can cause property damage, injury or death.
UL73 grounding instruc-
tions: This appliance must be connected to a
grounded, metal, permanent wiring system. Or
an equipment-grounding conductor must be run
with the circuit conductors and connected to
the equipment-grounding terminal or lead on the
appliance. Failure to comply with this procedure
can cause property damage, injury or death.
2
Appliances equipped with a
flexible electric supply cord, are provided with a
grounding plug. It is imperative that this plug be
connected into a properly grounded receptacle.
Failure to comply with this procedure can cause
property damage, injury or death.
If the receptacle is not the
proper grounding type, contact an electrician. Do
not remove the grounding prong from the plug.
Failure to comply with this procedure can cause
property damage, injury or death.
Before performing any service
that involves electrical connection or disconnec-
tion and/or exposure to electrical components,
always perform the Electrical LOCKOUT/TA-
GOUT Procedure. Disconnect all circuits. Failure
to comply with this procedure can cause prop-
erty damage, injury or death.
Before removing any sheet
metal panels or servicing this equipment, al-
ways perform the Electrical LOCKOUT/TAGOUT
Procedure. Be sure all circuits are disconnected.
Failure to comply with this procedure can cause
property damage, injury or death.
Do not operate this equipment
without properly placing and securing all covers
and access panels. Failure to comply with this
procedure can cause property damage, injury or
death.
Do not use or store gasoline or
other flammable vapors or liquids in the vicinity
of this or any other appliance. Failure to comply
can cause property damage, injury or death.
In the event of a power failure,
do not attempt to operate this appliance. Failure
to comply can cause property damage, injury or
death.
 Service Manual for Flexible Batch Broiler Units

TABLE OF CONTENTS
INTRODUCTION...................................................................................................................................5
INSTALLATION................................................................................................................................5
OPERATION....................................................................................................................................5
CLEANING......................................................................................................................................5
SPECIFICATIONS.................................................................................................................................6
MODEL NUMBER KEY...................................................................................................................6
TOOLS............................................................................................................................................6
REMOVAL AND REPLACEMENT OF COMPONENTS........................................................................7
COVERS AND PANELS..................................................................................................................7
Fuse Access Panel....................................................................................................................7
Element Connection Access Panel............................................................................................7
Electrical Access Panel..............................................................................................................7
Product Pan Shelf......................................................................................................................8
Discharge Hood.........................................................................................................................8
Discharge Chute........................................................................................................................8
Discharge Pan...........................................................................................................................8
Discharge Grease Pan..............................................................................................................9
Discharge Access Panel............................................................................................................9
Main Grease Pan.....................................................................................................................10
Grease V-Pan..........................................................................................................................10
Loader Tray..............................................................................................................................10
Conveyor Drive Motor Cover...................................................................................................11
Top Service Panel....................................................................................................................11
Removing the Front Panel.......................................................................................................12
Removing the Rear Panel........................................................................................................12
Removing the Element Cover Panel........................................................................................12
COMPONENT REMOVAL.............................................................................................................13
Conveyor Drive Motor Assembly.............................................................................................13
Conveyor Drive Chain........................................................................................................14
Conveyor Drive Motor Sprocket.........................................................................................14
Conveyor Drive Motor Capacitor.......................................................................................15
Cook Chamber Temperature Probe.........................................................................................16
Control Board...........................................................................................................................17
Step-Down Transformer...........................................................................................................17
Solid-State Relays...................................................................................................................18
Main Power Switch..................................................................................................................18
Mechanical Relays...................................................................................................................19
Replacing Conveyor Links.......................................................................................................19
HEATING ELEMENTS..................................................................................................................20
FUSE REPLACEMENT.................................................................................................................22
ADJUSTMENTS..................................................................................................................................23
DRIVE CHAIN DEFLECTION ADJUSTMENT...............................................................................23
CONVEYOR POSITION ADJUSTMENT.......................................................................................23
ASH SCRAPER BRACKET ADJUSTMENT..................................................................................24
LOADER DOOR SEAL BRACKET................................................................................................24
PRODUCT STOP BRACKET ADJUSTMENT...............................................................................25

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Service Manual for Flexible Batch Broiler Units

SEQUENCE OF OPERATION........................................................................................................... 26
TROUBLESHOOTING........................................................................................................................27
COMPONENT CHECK PROCEDURES.......................................................................................27
Checking the Power Switch.....................................................................................................27
Checking the Control Board.....................................................................................................27
Testing the Temperature Probe................................................................................................27
Checking the Conveyor Drive Motor........................................................................................27
Testing the Conveyor Drive Motor...........................................................................................28
Checking Conveyor Drive Motor Capacitor.............................................................................28
Testing the Relays...................................................................................................................28
Testing the Transformers.........................................................................................................29
Voltage Test.......................................................................................................................29
Resistance Check..............................................................................................................29
Testing the Mechanical Relays................................................................................................29
Continuity Test...................................................................................................................29
Testing the Contactors.............................................................................................................29
Voltage Test.......................................................................................................................29
CONTROL DIAGNOSTICS...........................................................................................................30
Programming...........................................................................................................................30
Diagnostics..............................................................................................................................30
TROUBLESHOOTING CHART.....................................................................................................32
PREVENTIVE MAINTENANCE...........................................................................................................35
ELECTRICAL SCHEMATIC – FLEXIBLE BATCH BROILER..............................................................36
CUSTOMER ASSISTANCE.................................................................................................................39

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 Service Manual for Flexible Batch Broiler Units

INTRODUCTION
INSTALLATION CLEANING
For detailed installation instructions, refer to the For specific cleaning instructions, refer to the
Installation and Operation Manual. Installation and Operation Manual.

OPERATION
For specific operating instructions, refer to the
Installation and Operation Manual.

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Service Manual for Flexible Batch Broiler Units

SPECIFICATIONS
ELECTRICAL
MODEL NUMBER VOLTAGE AMPS CYCLE PHASE POWER CATALYST
FBB-EO-208 208 68 60 3 23.5 kW NO
FBB-EC-208 208 68 60 3 23.5 kW YES
FBB-EO-230 230 62 60 3 23.5 kW NO
FBB-EC-230 230 62 60 3 23.5 kW YES
FBB-EO-240 240 60 50 3 23.5 kW NO
FBB-EC-240 240 60 50 3 23.5 kW YES

SHIPPING
lbs Kg
WEIGHT
BATCH BROILER
530 240
(STANDARD)

SHIPPING
Standard Metric (cm)
DIMENSIONS
LXWXH 47" X 34" X 68" 119.4 X 86.4 X 172.7

MODEL NUMBER KEY TOOLS

FBB–EX-Y-ZZ STANDARD
X = O (No Catalyst) or C (Catalyst) • Standard set of hand tools.
Y = 208 VAC, 230 VAC or 240 VAC • Volt-Ohm Meter (VOM) with AC current
ZZ = 2 Digit Country Identifier clamp
(Any quality VOM with a sensitivity of at
least 20,000 ohms per volt can be used).
• Conveyor Link Removal Pliers

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 Service Manual for Flexible Batch Broiler Units

REMOVAL AND REPLACEMENT OF COMPONENTS

COVERS AND PANELS 1. First remove Fuse Access Panel. Refer to the
COVERS and PANELS section of the manual.
2. Remove Element Connection Access Panel
WARNING by lifting up and removing from broiler
3. Install Electrical Connection Access Panel by
DISCONNECT THE ELECTRICAL lowering into the side grooves.
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES. Electrical Access Panel

The Electrical Access Panel provides access to

Caution: If the broiler has been operating, the Transformers, Blower Motor, Conveyor Motor
broiler panels and components Capacitor, and electrical connections to the Control
may be hot. Use PROPER Board.
PROTECTION.
1. Remove the six screws securing the Electrical
Access Panel.
Fuse Access Panel
2. Remove the panel from the broiler.
The Fuse Access Panel provides access to the
Upper Flame Sensors, Igniters and Blower Hose. 3. Reverse procedure to install the Electrical
Access Panel.
1. Remove Fuse Access Panel by lifting up and
removing from broiler.
2. Install Fuse Access Panel by lowering into the
side grooves.

Screws

Fuse Element
Access Connection
Panel Access
Panel

Electrical Access Panel

Product Pan Shelf

Upper Access Panels The Product Pan Shelf is located on the discharge
side of the broiler and holds the unused holding
Element Connection Access Panel pans.
The Element Connection Access Panel provides
access to the electrical connection for the Heating 1. Lift the pan shelf up and remove.
Elements.

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Service Manual for Flexible Batch Broiler Units

2. To install the pan shelf, slide the keyholes over

the two screws and slide pan shelf down. Pin

Product
Pan
Shelf

Discharge
Hood
Pin
Discharge
Chute Hook

Discharge Chute

Product Pan Shelf and Discharge Hood
Discharge Hood
The Discharge Hood is located on the discharge
side of the broiler under the Product Pan Shelf.
1. Remove the Product Pan Shelf.
2. Remove the Discharge Hood by lifting out.
3. Install Discharge Hood by lowering into the
side grooves.
4. Reinstall the Product Pan Shelf.
Discharge Pan
The Discharge Pan is located on the discharge
side of the broiler below the Discharge Hood and
is used to support the Product Pan (not supplied).
1. Remove the Product Pan if present.
2. Slide Discharge Pan up and out of keyhole
slots.
3. Install Discharge Pan by lowering it into the
thumbscrews.
Discharge
Pan

Discharge Chute
The Discharge Chute is located under the
Discharge Hood and guides the patties from the
conveyor into the Discharge Pan.
1. Remove Product Pan Shelf.
2. Remove the Discharge Hood.
3. Remove Discharge Chute by lifting off of the
two side pins.
4. Reverse procedure to install Discharge Chute,
Discharge Pan
being sure to rest the hooks onto the pins on
both sides.
Discharge Grease Pan
The Discharge Grease Pan is located below the
Discharge Pan and catches any grease drippings.

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 Service Manual for Flexible Batch Broiler Units

1. Tilt Discharge Grease Pan up to unhook and

pull forward to remove.
2. When installing the Discharge Grease Pan,
be sure to tilt up and push all the way back.

NOTE: Correct positioning will not allow pan

removal without upward tilt.

Discharge
Side
Access
Panel

1
Discharge Access Panel
2
Main Grease Pan
Discharge The Main Grease Pan is located on the front of
Grease
Pan the broiler under the Grease V-Pan.
Remove the Main Grease Pan by sliding straight
Discharge Grease Pan out of broiler.

Discharge Access Panel

1. Remove the PHU Pan Shelf.
2. Remove Discharge Hood.
3. Remove Discharge Chute.
4. Remove Discharge Pan.
5. Remove Discharge Grease Pan.
6. Remove Discharge Access Panel by lifting it
up and out.
7. Reverse procedure to install Discharge Access
Panel.

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Service Manual for Flexible Batch Broiler Units

Grease V-Pan 2. Remove Loader Tray from the Loader Brackets

The Grease V-Pan is located on the front of the
broiler under the Loader Tray.
Remove pan by sliding straight out from broiler.
by pulling forward and disengaging ears on
Loader Tray from keepers on the Loader
Brackets.
3. Install Loader Tray by sliding it into bracket
and engaging ears with keepers.

Loader
Carriage
Grease
V-Pan Ear Loader
Bracket
Main
Grease Pan

Grease V-Pan and Main Grease Pan Loader Tray

Loader Tray Conveyor Drive Motor Cover

The Loader Tray is located on the front of the The Conveyor Drive Motor Cover, located on the
broiler and slides into the channels on the Loader lower front of the broiler on the discharge side,
Brackets. covers the Drive Chain Motor.

1. Remove Loader by sliding it out of the Loader 1. Remove the Main Grease Pan and the Grease
Tray. V-Pan.

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 Service Manual for Flexible Batch Broiler Units

2. Remove the three screws securing the cover 3. Reverse procedure to install the perforated
to the broiler. Top Service Panel.
3. Lift Conveyor Drive Motor Cover off the broiler.

Catalyst
Guard

Top
Service
Panel

Conveyor
Drive
Motor
Cover

Conveyor Drive Motor Cover

Top Service Panel

The perforated Top Service Panel provides access
to the two Infrared Burners
Top Service Panel
1. Remove the four screws securing the
perforated Top Service Panel.
Removing the Front Panel
2. Remove the perforated Top Service Panel
from the broiler. 1. Slide the Loader out of the Loader Tray.
2. Unlatch the Loader Tray and slide it out of the
Loader Tray Mounting Brackets.
3. Pull the Main Grease Pan out of the front of
the broiler.

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Service Manual for Flexible Batch Broiler Units

4. Pull the Grease V-Pan out of the front of the

broiler.
5. Lift Front Panel up and away from broiler.
6. Reverse these steps to reinstall these parts.

Front Access Panel

Rear Access Panel

Removing the Element Cover Panel

1. Remove the Rear Panel
2. Lift the Element Cover Panel up and away
Front Panel and remove from the broiler.

Removing the Rear Panel

1. Remove Cotter pin and unfasten latch.

Element Cover Panel

Rear Panel Cotter Pin & Latch
2. Lift Rear Panel up and away from broiler.
3. Reverse to reinstall the Rear Panel.
3. The Panel is connected to the broiler with
safety cables. Swing the panel up and place
it on top of the broiler.
4. Reverse to reinstall the Element Cover Panel.

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 Service Manual for Flexible Batch Broiler Units

COMPONENT REMOVAL
CONVEYOR DRIVE MOTOR ASSEMBLY 7. Reverse procedure to install a new motor.
Ensure that one of the sprocket set screws is
The Conveyor Drive Motor Assembly is located tightened to the flat side of the motor shaft.
in the lower front of the broiler at the discharge
end. The motor drives the Conveyor by use of a
drive chain. NOTE: When installing the new motor, be sure
to engage the chain on the motor sprocket.
Adjust the tension on the chain to allow 3/16"
chain deflection, as described in the procedure
WARNING
DRIVE CHAIN DEFLECTION ADJUSTMENT
DISCONNECT THE ELECTRICAL in the ADJUSTMENT Section, before tightening
the motor mounting plate screws.
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
Screws Motor
Assembly
1. Remove the Conveyor Drive Motor Cover.
Refer to the COVERS and PANELS section
of the manual.
2. Disconnect wires to motor.
3. Remove Discharge Access Panel. Refer to the
COVERS and PANELS section of the manual.
4. Remove four screws securing motor to
mounting plate and remove motor. Motor
Mounting
5. Raise motor mounting plate to disengage drive Plate
chain from motor pulley.
6. Remove sprocket from motor shaft. Sprocket Conveyor Drive Motor Assembly
is secured to motor shaft by two set screws.
CONVEYOR DRIVE CHAIN
The Conveyor Drive Chain connects the drive
motor to the Conveyor.

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Service Manual for Flexible Batch Broiler Units
WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
Chain
Motor
Sprocket
Drive Chain and Sprockets
1. Remove Conveyor Drive Motor Cover. Refer
to the COVERS and PANELS section of the
manual.
2. Remove Discharge Access Panel. Refer to the
COVERS and PANELS section of the manual.
3. Disconnect motor wires.
4. Remove four screws securing motor
mounting plate.
5. Raise motor mounting plate to disengage drive
chain from motor sprocket.
6. Disengage chain from conveyor sprocket.
7. Remove chain from broiler by removing the
master link.
8. Reverse procedure to install a new chain.
14
NOTE: When installing the new chain, be sure
to engage the chain on the motor sprocket and
conveyor sprocket. Then adjust the tension
on the chain to allow 3/16" chain deflection,
as described in the procedure DRIVE
CHAIN DEFLECTION ADJUSTMENT in the
ADJUSTMENT Section, before tightening the
motor mounting plate screws.
CONVEYOR DRIVE MOTOR SPROCKET
The Conveyor Drive Motor Sprocket is attached
to the motor shaft.
WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
1. Remove Conveyor Drive Motor Cover. Refer
to the COVERS and PANELS section of the
manual.
2. Remove Discharge Access Panel. Refer to the
COVERS and PANELS section of the manual.
3. Disconnect the motor wires.
4. Remove the four screws securing motor
mounting plate.
5. Raise motor mounting plate to disengage drive
chain from motor sprocket.
6. Disengage drive chain from motor sprocket.
7. Loosen the two setscrews on motor sprocket
and remove sprocket from motor shaft.
8. Reverse procedure to install a new Conveyor Drive
Motor Sprocket, ensuring that one set screw is
tightened to the flat side of the motor shaft.
NOTE: When installing the new Conveyor Drive
Motor Sprocket, be sure to engage the chain on
the motor sprocket and conveyor sprocket, then
adjust the tension on the chain to allow 3/16"
chain deflection as described in the procedure
DRIVE CHAIN DEFLECTION ADJUSTMENT
in the ADJUSTMENT Section, before tightening
the motor mounting plate screws.
 Service Manual for Flexible Batch Broiler Units

CONVEYOR DRIVE MOTOR CAPACITOR 5. Reverse procedure to install a new Conveyor

Drive Motor Capacitor.

WARNING

DISCONNECT THE ELECTRICAL

POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT Conveyor
PROCEDURES. Drive Motor
Capacitor

1. Remove Electrical Access Panel. Refer to the

COVERS and PANELS section of the manual.
2. Disconnect wires to Conveyor Drive Motor
Capacitor.
3. Discharge the capacitor Apply a short across Conveyor Drive Motor Capacitor
the two capacitor terminals.
4. Remove screw securing capacitor to frame
and remove Conveyor Drive Motor Capacitor.

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Service Manual for Flexible Batch Broiler Units

COOK CHAMBER TEMPERATURE PROBE
The Cook Chamber Temperature Probe connects
to the bottom of the Control Board and is located
on the back of the broiler.
9. Slide new compression nut, fitting and sleeve
onto Temperature Probe sheath.
10. Insert Temperature Probe into tube fully and
tighten compression nut.

Cook Chamber
WARNING Temperature Probe
Connection
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.

1. Remove the Electrical Access Panel. Refer

to the COVERS and PANELS section of the
manual.
2. Remove the Rear Panel. Refer to the COVERS
and PANELS section of the manual.
3. Remove the two screws that secure the Control
Cook Chamber Temperature Probe
Board Bezel.
Connection
4. Disconnect the Cook Chamber Temperature
Probe connector at the bottom of the Control
Board.
5. Remove the Cook Chamber Temperature
Probe from the broiler by loosening the
compression nut.
Cook Chamber
6. Slide the Cook Chamber Temperature Probe Temperature Probe
out of the broiler.
7. Route new Temperature Probe through Control
Shroud and through panel.
8. Make connection at the Control Board and
replace Control Board Bezel.
Compression
Nut

Cook Chamber Temperature Probe Mounting

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 Service Manual for Flexible Batch Broiler Units

Control Board Step-Down Transformer

The Control Board is located on the front of the
broiler. Control Board programming is preset at
the factory with standard BURGER KING® recipes.
Any fine adjustments made at the restaurant level
are the responsibility of the restaurant manager.
The Step-down Transformer is accessible by
removing the Electrical Access Panel. The
Transformer reduces the incoming voltage to
24 VAC.

WARNING
WARNING
DISCONNECT THE ELECTRICAL
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
PROCEDURES.

1. Remove the Electrical Access Panel. Refer to the 1. Remove the Electrical Access Panel. Refer
COVERS and PANELS section of the manual. to the COVERS and PANELS section of the
manual.
2. Remove the two screws on the front of the
Control Board. 2. Disconnect wires from the Transformer to be
removed.
3. Disconnect the Cook Chamber Temperature
Probe connector at the bottom of the Control 3. Remove screws securing Transformer to
Board. frame.
4. Disconnect the 9-pin and 12-pin connectors 4. Remove Transformer.
from the back of the Control Board Bezel..
5. Reverse procedure to install a Transformer.
5. Remove Control Board from broiler.
6. Reverse procedure to install new Control
Board.
Step-Down
7. Alert the restaurant manager the Control Board Transformer
has been replaced and fine adjustments may
be required.

9-Pin and
12-Pin
Screws Connectors

Step-Down Transformers

Cook Chamber
Temperature
Probe

Control Board

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Service Manual for Flexible Batch Broiler Units

SOLID-STATE RELAYS MAIN POWER SWITCH

The Solid-State Relays are accessible by removing The Main Power Switch is located on the front of
the Electrical Access Panel. There are a total of the broiler below the Control Board.
Seven SSR’s. Six control the heating elements
and one controls the conveyor motor.
Please note that there are three types of Solid WARNING
State Relays used within the broiler. Each has
DISCONNECT THE ELECTRICAL
separate input and output operating voltages, as
POWER TO THE BROILER AND
well as different maximum output current ratings.
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.

WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
1. Remove Electrical Access Panel. Refer to the
COVERS and PANELS section of the manual.
2. Disconnect switch wires.
3. Pinch the spring tabs on the top and bottom of
the switch and slide out through front of panel.

1. Remove the Panel. Refer to the COVERS and 4. Reverse procedure to install a new Main Power
PANELS section of the manual. Switch.

2. Disconnect wires from the Solid-State Relay

to be removed. Control
Board
3. Remove screws securing Solid-State Relay
to frame.
4. Remove Solid-State Relay.
5. Peel protective film which covers the thermal
compound pad on the back of the new Solid
State Relay before replacing.
Main
6. Reverse procedure to install a Solid-State Power
Switch
Relay.

Solid State
Main Power Switch
Relays

Solid State Relays

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 Service Manual for Flexible Batch Broiler Units

MECHANICAL RELAYS REPLACING CONVEYOR LINKS

The Mechanical Relays are accessible by
removing the Electrical Access Panel. There are
Two Mechanical Relays that are used in the Safety
Panel Interlock system.
WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
1. Remove Electrical Access Panel. Refer to the
COVERS and PANELS section of the manual.
2. Disconnect wires from the Mechanical Relay
to be removed.
3. Remove screws securing Mechanical Relay
to frame.
WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
1. Turn off and unplug the broiler.
2. Remove the front operator parts and panels.
Refer to the COVERS and PANELS section
of the manual.
3. Spread the damaged link with Link Tool at both
ends.
4. Remove the damaged link.
5. Install the new link.
6. Use pliers to close both ends of the link.

4. Remove Mechanical Relay. 7. Check for proper operation. It may be

necessary to add or remove shims behind or
5. Reverse procedure to install an Mechanical under the bushing blocks to ensure proper
Relay. tension.

NOTE: Never remove a link without replacing

a link.
Mechanical
Relays
Spread links

Mechanical Relays

Conveyor Links

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Service Manual for Flexible Batch Broiler Units

HEATING ELEMENTS

WARNING

DISCONNECT THE ELECTRICAL

POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.

2. Lift and remove rear access panel.

NOTE: In the event of an element failure, the 3. Remove the element cover panel. Refer to the
Controller will display an error message and
COVERS and PANELS section of the manual.
indicate which element has failed. Refer to
the Troubleshooting Label on the right side of
the Broiler to identify the appropriate element
location. The controller will display:
• Ht:1
• Ht:2
• Ht:3
• Ht:4
• Ht:5
• Ht:6 4. Remove the Fuse Access Panel and the
Element Connection Access Panels. Refer
1. Turn off power and unplug the Broiler. to the COVERS and PANELS section of the
manual.
5. Disconnect the appropriate element plug
from the interior panel by squeezing in the
connector’s tabs.

20
 Service Manual for Flexible Batch Broiler Units

6. Disengage the clip by first removing the 9. Slide element module in place and reengage
retaining pin on both top and bottom of clips and re-insert retaining pins.
element module.

10. Reengage clips and re-insert retaining pins.

7. Pull clip forward to disengage.

8. Slowly remove element module and replace

with identical configuration. Replacement
element must also be slid into support bracket
at the front of the Broiler (Clips and Hooks will
not align properly if the wrong element module
is re-inserted.)

11. Reconnect element connector to interior panel

connector.
12. Reinstall the Element Cover Panel.
13. Reinstall the Rear Panel and fasten the
retaining latch.
14. Reinstall the Element Access Panel.
15. Plug in the Broiler.
16. Turn on the Main Power Switch.

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Service Manual for Flexible Batch Broiler Units

FUSE REPLACEMENT 4. Replace any blown fuse(s) with correctly rated

replacement fuse(s).
1. Check the fuses on the Fuse Panel. A lit
Indicator lamp means a blown fuse.

5. Close the fuse holder. Plug in the broiler and

check the indicator lamps. They should not be
2. Unplug the broiler. lit with a good fuse in place.
6. Reinstall the Fuse Access Panel
7. Broiler will go into preheat mode indicating
proper operation.

3. Open the fuse holder(s) to remove any blown

fuse(s).

NOTE: This unit also comes equipped with

a safety interlock system located on the rear
access panel for additional user safety. The
rear access panel must be mounted correctly or
power will not be supplied to heating elements.

22

ADJUSTMENTS
DRIVE CHAIN DEFLECTION ADJUSTMENT
The Drive Chain connects the drive motor to the
Conveyor.
1. Check that the deflection in the Drive Chain
does not exceed 3/16" inch maximum. If
the chain requires adjustment, proceed to
step 2.
2. Remove Discharge Access Panel. Refer to the
COVERS and PANELS section of the manual.
3. Remove Conveyor Drive Motor Cover.
4. Loosen the four screws securing the motor
mount to the frame.
5. Move the motor mount up or down as necessary
to provide 3/16" deflection at center of chain.
6. Secure the motor mount in place by tightening
the four motor mount screws.
7. Install Conveyor Drive Motor Cover.
8. Install Discharge Access Panel.
INSIDE VIEW Motor
Mount
Screws
Drive Chain Deflection Adjustment
Service Manual for Flexible Batch Broiler Units
CONVEYOR POSITION ADJUSTMENT
The Conveyor position is adjusted by adding
shims between the Conveyor Shaft Bearing and
the frame.
1. Remove Discharge Hood to provide visual
access to the Conveyor.
2. Adjust Conveyor height as described in the
following illustration.
3. Remove the two screws securing the bearing
to the frame.
4. Insert shims as necessary between the bearing
assembly and the frame.
5. Check Conveyor position.
NOTE: Leading edge of Discharge Chute should
be about an 1/8" above the center line of the
Conveyor shaft. When correctly adjusted, the
Conveyor link should just graze the backside of
the chute. If adjusted too high, the link will roll
over the top of the leading edge of the Discharge
Chute causing a Conveyor jam.
6. If additional shims are required, repeat step 4.
NOTE: Additional shims are located inside the
Drive Motor Cover.
7. Use the Diagnostic Mode on the Control to
run the Conveyor for several full revolutions
to confirm that no jamming occurs.
Position 1/8" above
center line of
conveyor shaft.
Discharge Conveyor
Chute Shaft
Conveyor Discharge Shaft Adjustment
23
Service Manual for Flexible Batch Broiler Units

ASH SCRAPER BRACKET ADJUSTMENT LOADER DOOR SEAL BRACKET

The Ash Scraper Bracket support the Ash Scraper
on the Discharge end of the Broiler.
1. Remove Discharge Access Panel. Refer to the
COVERS and PANELS section of the manual.
2. Loosen three nuts which secure the Ash
Scraper Bracket and adjust bracket up or down
as needed.
The Loader Door Seal Bracket supports the Loader
Door and assists to seal any gap between the
Loader Door and the Loader Ramp.
1. Remove the Loader Door.
2. Loosen three nuts which secure the Loader
Seal Door Bracket and adjust bracket up or
down as needed.

Loader Door
Seal Bracket
Loosen nuts
Ash Scraper
Bracket

Loosen nuts Loader

Door

Ash Scraper Bracket Adjustment Loader Door Seal Bracket

24
 Service Manual for Flexible Batch Broiler Units

Product Stop Bracket Adjustment

The Product Stop Bracket sits above the cook chain
on the back wall of the cook cavity. It prevents
product from being loaded and pushed up on top
of the cook chain links.
1. Remove the Rear Panel and Element Cover
Panel. Refer to the COVERS and PANELS
section of the manual.
2. Loosen three nuts which secure the Product
Stop Bracket and adjust bracket up or down
as needed.

Product Stop Bracket

Loosen nuts

Product Stop Bracket Adjustment

25
Service Manual for Flexible Batch Broiler Units

SEQUENCE OF OPERATION
TURN ON Read†Temperature
NOTE: Diagnostics – See TROUBLESHOOTING for
possible Display results.

Diagnostics

Read†Temperature

Loop†Until†Temperature
†“iSEt”†(740F†[393C])

Idle Cycle: Top Elements

Temperature
YES cycle by “iPL” = 6
†740F†(393C)?
ON: 6 sec, OFF: 4 sec

Turn LEDs for

Product Keys
with Non-Zero
Display†“Lo” Cook Time Discharge: run
GREEN Cook chain for
NO “Cdti” time
(6-8 sec)
NO
Turn Off “DO NOT
LOAD” LED
Output & enable Diagnostics
Product Key
Bottom & Top buttons
Temperature
Elements ON
<†300F†(149C)?
continuously Bottom Elements cycle
Diagnostics based on “SEt1-6”
(Setpoint Temperature)
Turn LEDs for Product YES and “bh1-6”
YES Bottom Elements cycle
YES Keys with Non-Zero (Booster Heater, ON/OFF)
to maintain within 10F
Cook Time RED (6C) of iSEt

Display†“PrE” Top Elements cycle

Turn†On “DO NOT based on “ti1-6”
LOAD” LED Output & (Time Segment) &
disable Product Key Temperature “PL1-6” (Power Level)
buttoms <†iSEt - “Lo t”
640F†(337C)? NO

Idle Cycle: Top Elements NO Cook time

Loop†Until†Temperature
cycle by “iPL” = 6 expired?
†“iSEt”†(740F†[393C])
ON: 6 sec, OFF: 4 sec
Temperature
>†iSEt - “Hi t”
940F†(504C)? NO
Read†Temperature
Loop for Cook Cycle:
10 minutes Product Key
depressed
Diagnostics YES Display†“rdy”

Bottom Elements cycle

to maintain within 10F Loop until a
(6C) of iSEt Display†“Hi” Product Key is
pressed

Diagnostics

26

TROUBLESHOOTING
The following troubleshooting information includes
checking procedures for various electrical
components in order to help identify faulty
components. The troubleshooting guide below is
designed to identify various symptoms and provide
the suggested remedy.
COMPONENT CHECK PROCEDURES
Checking the Power Switch
The Power Switch has a built-in LED that lights
red when the switch is in the on position. Check
the following before replacing the switch.
• Make sure the power cord is plugged into the
correct receptacle. The broiler operates on
208/240 VAC 60 Hz line current.
• Check the circuit breaker assigned to the
broiler.
• Try a different receptacle before replacing the
switch.
• It’s possible for the LED in the switch to fail.
Turn the switch on and check the Control
Board display. If the display is active, the LED
is burned out, replace the switch.
Checking the Control Board
Under normal conditions, the Control Board
displays the current status of the broiler. It can
be used as a diagnostic tool, when it is working
properly.
Try the following before replacing the Control
Board.
• Cycle the broiler off and on; observe the Control
Board.
• Try running the Control Board through a couple
of different cook cycles.
Service Manual for Flexible Batch Broiler Units
NOTE: If the Control Board is still not performing
properly, try these procedures:
1. Turn the broiler off.
2. Remove the Control Board.
3. Check each connection on the back of
the Control Board. Make sure they are all
connected correctly.
4. Loosely attach the Control Board, turn the
broiler on. Observe the display and product
key LEDs.
5. Turn the power off and reattach the Control
Board if the problem is solved.
Testing the Temperature Probe
1. Turn the broiler OFF.
2. Remove two screws which secure the Control
Board Bezel, and remove the Control Board.
3. Disconnect the Temperature Probe connector
at the bottom of the Control Board.
4. Use an Ohmmeter to check resistance on
the Temperature Probe. An open or shorted
measurement would indicate a fault.
Checking the Conveyor Drive Motor
The Conveyor Drive Motor is located on the front
of the broiler on the lower discharge side. Before
replacing it, check the Conveyor for jammed meat
product. Next, try turning the Conveyor discharge
shaft with the Multipurpose Broiler Tool. If the
Conveyor does not turn, check the following items:
• Check the Discharge Chute.
• Check the Loader Ramp.
• Check the Ash Scraper.
• Check the Cook Chain (Conveyor).
• Check the Flame Arrestor.
27
Service Manual for Flexible Batch Broiler Units

Testing the Conveyor Drive Motor 3. Discharge the Capacitor by shorting both
terminals to ground at the same time.
The Conveyor Drive Motor may be tested without
removing it from the broiler. 4. Use an Ohmmeter to test the Capacitor.

NOTE: If both the Drive Motor and Capacitor

WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
1. Turn off and disconnect the broiler.
test OK, the problem is probably with the Drive
Motor Relay.
Testing the Relays
There are seven Solid-State Relays in the broiler.
Six control the Heating Elements, while the other
controls the Conveyor Drive Motor.

2. Remove the Conveyor Drive Motor Cover.

3. Tag and disconnect the wires.
4. Use an Ohmmeter to measure resistance.
5. Attempt to run the Drive Motor when it’s
disengaged from the Drive Chain.
NORMAL MOTOR RESISTANCE (230 VAC, 60 HZ)
Wires to Test Resistance
Black and Brown 98.1 Ω
Black and Orange 98.1 Ω
Brown and Orange 196.2 Ω
Checking Conveyor Drive Motor Capacitor
If the motor tests OK, check the Capacitor. The
Capacitor is located in the service area on the
control side of the broiler.
WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
1. Remove the Electrical Access Panel. Refer
to the COVERS and PANELS section of the
manual.
2. Turn ON the Main Power Switch.
3. The Heating Elements are energized when
the Controller calls for heat. To test the relay,
check for voltage on the input of the relay. See
the chart below. At the same time, monitor
AC current to Heating Elements. When no
relay input voltage is present, there will be no
amperage draw on the output of the relay.

WARNING NOTE: (SSR4) is unique and operates with

a DC voltage input
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
Input Typical Max.
FOLLOW LOCKOUT / TAGOUT
Relay # Voltage Voltage Output
PROCEDURES. Range Reading Amps
SSR1 18-36 VAC 24 VAC 50 A
1. Remove the Electrical Access Panel. Refer SSR2 18-36 VAC 24 VAC 50 A
to the COVERS and PANELS section of the
SSR3 18-36 VAC 24 VAC 50 A
manual.
SSR4 4-32 VDC 6 VDC 50 A
2. Disconnect the wires connected to the SSR5 18-36 VAC 24 VAC 50 A
Capacitor.
SSR6 18-36 VAC 24 VAC 50 A

28

The Conveyor Drive Motor runs when the Drive
Motor Relay is energized by the Control.
The Solid State Relay that controls the Conveyor
Drive Motor, utilizes a 4.5 - 32 VDC (typically 6
VDC) input signal to switch up to 10A on the output.
TESTING THE TRANSFORMERS
The 24-volt Step-Down Transformer in the broiler
supplies power to the Control Board. Either a
voltage or a resistance check can be used to test
the Transformer.
Voltage Test
1. Make sure the broiler is turned OFF.
2. Remove the Electrical Access Panel. Refer
to the COVERS and PANELS section of the
manual.
3. Disconnect the secondary winding.
4. Turn the broiler on.
5. Using a VOM, test the voltage output across
the secondary winding. Voltage should be
24 VAC.
Resistance Check
WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
1. Turn the broiler OFF.
2. Remove the Electrical Access Panel. Refer
to the COVERS and PANELS section of the
manual.
3. Tag and disconnect the wires of the Transformer
to be tested.
4. Measure the resistance across the primary.
Primary Resistance = 71.5 Ω ±10%.
5. Measure resistance across secondary.
6. Secondary Resistance = 1.3 Ω ±10%.
Service Manual for Flexible Batch Broiler Units
TESTING THE MECHANICAL RELAYS
The two Mechanical Relays work in conjunction
with the safety interlocks to allow safe access to
the various areas of the Broiler.
When working properly, they allow AC input voltage
to the two Contactors, which allow the elements
to heat.
Continuity Test
1. Make sure broiler is turned OFF.
2. Remove the Electrical Access Panel. Refer
to the COVERS and PANELS section of the
manual.
3. Disconnect a single contact terminal on the
Mechanical Relay and tape off for safety.
4. Turn the broiler on.
5. Test continuity across the two contact
terminals. With Safety Interlock panels
installed, continuity should be present.
TESTING THE CONTACTORS
The two Contactors in the broiler lie in series with
each other and supply power to the Elements.
Voltage Test
1. Make sure the broiler is turned OFF.
2. Remove the Electrical Access Panel. Refer
to the COVERS and PANELS section of the
manual.
3. Turn the broiler on.
4. Visually validate that the Contactor is energizing
and “pulling in”.
5. If Contactor does not energize, ensure
208/240 VAC is present at the input coil.
29
Service Manual for Flexible Batch Broiler Units

CONTROL DIAGNOSTICS
The Broiler Control consists of two programming modes and two diagnostic modes. To enter any of these
4 modes, it is required to first hold down the ENTER button for a few seconds until CODE is displayed.
Then enter the 4 digit passcode provided below and press ENTER.

Programming
1. Recipe related programming (Refer to Owner’s Manual)
Passcode: 1 8 2 7
2. Broiler functionality programming (Refer to Owner’s Manual)
Passcode: 3 6 4 5

Diagnostics
1. Diagnostic Test
Passcode: 3 4 2 4
After entering the code and pressing ENTER, DIAG will be displayed and then
the display will show 8888.
The following options are available:
a) Pressing the key will run the Conveyor Drive Motor.
NOTE: Do not run the Conveyor Drive Motor for more than 6 seconds at a time. It will overheat.
Pressing the key a second time will energize the Cook Light.
b) Pressing the key once will initiate an Element Diagnostic test with
the TOP ELEMENTS ON only.
a. S1 = H1 Current
b. S2 = H2 Current
c. S3 = H3 Current
c) Pressing the key a second time will initiate an Element Diagnostic test with
the BOTTOM ELEMENTS ON only.
a. S1 = H4 Current
b. S2 = H5 Current
c. S3 = H6 Current
d) Pressing the key a third time will initiate an Element Diagnostic test
with ALL ELEMENTS OFF.
a. S1 = H1 & H4 Current
b. S2 = H2 & H5 Current
c. S3 = H3 & H6 Current
e) Pressing the key a fourth time will go back to the home screen, 8888.
f ) Pressing the ENTER button from here will exit Diagnostic mode.

30
 Service Manual for Flexible Batch Broiler Units

2. Failure Counts
The Control Board keeps track of how many times product buttons are depressed. It also tracks
Element failures and other various failures as shown below.
Passcode: 1 2 3 4
Prd1 = Prd1 depressions
Prd2 = Prd2 depressions
Prd3 = Prd3 depressions
Prd4 = Prd4 depressions
Prd5 = Prd5 depressions
Prd6 = Prd6 depressions
Prd7 = Prd7 depressions
Prd8 = Prd8 depressions
tP1 = HT1 Element failures
tP2 = HT2 Element failures
tP3 = HT3 Element failures
tP4 = HT4 Element failures
tP5 = HT5 Element failures
tP6 = HT6 Element failures
SrEr = Failures of ALL ELEMENTS OFF Element Diagnostic Test
dBEr = Communication failures between Diagnostic Board and Control Board
rtot = Total Run Time (Hours)

31
Service Manual for Flexible Batch Broiler Units

TROUBLESHOOTING CHART

Symptom Cause Remedy

Verify 208/240 VAC, 3 phase, present at
receptacle. Confirm 208 VAC or 240 VAC on
No Power Serial Number Label.
Ensure 208/240 VAC, line-to-line, at incoming
terminal block.
Control display does not
light up Ensure 208/240 VAC across input / output of
On / Off Switch
switch.
Ensure 24 VAC across Transformer secondary
Transformer
winding.

Wiring Check for broken or improper wire connection.

Back Panel Safety

Check that back panel is safely secured.
Interlock

Element
Connection
Check that side panel is safely secured.
Access Panel
Safety Interlock
Display flashes Check alignment of Safety Magnets on back
“PnL” & “oFF” – Magnet Alignment
and side panels.
(Panel Off Error)
With panels installed, check for continuity on
Safety Interlock
Safety Interlocks.

Ensure Mechanical Relays energize when

Display shows “Ht:x”,
where x is 1,2,3,4,5,6 –
(Heater Error)
Mechanical Relay panels are installed. With panels installed.
measure 24 VAC at relay coils.
Check for 24 VAC on secondary of
Transformer
Transformer.
Identify correct Heater location and test
Element
continuity.
Fuse Test continuity of appropriate Fuse.
Ensure Solid State Relay switches ON / OFF
Solid State Relay at appropriate intervals. Test for closed or
open output condition.
Test Solid State Relay inputs for appropriate
Control
signal from control.
Wiring Check for broken or improper wire connection.

32

Symptom
Display shows “hT:Er” –
(Possible error during “PrE”)
Displays flashes “tESt” &
“Prod” – (Test Product)
Display shows “Hi” –
(High Temperature Error)
Display shows “Lo” –
(Low Temperature Error)
Display shows “Sr:Er” –
(Failure of “ALL OFF”
Diagnostic Test)
Display shows “dB:Er”
Service Manual for Flexible Batch Broiler Units
Cause Remedy
Identify correct Heater location and test
Element
continuity.
Fuse Test continuity of appropriate Fuse.
Ensure Solid State Relay switches ON / OFF
Solid State Relay at appropriate intervals. Test for closed or
open output condition.
Wiring Check for broken or improper wire connection.
Heat Loss Check for missing or damaged panels.
This error may occur at the end of a cook
Refer to “Ht:x”
cycle and should be followed by a “Ht:x” error.
Ensure Solid State Relay switches ON / OFF
Solid State Relay at appropriate intervals. Test for closed or
open output condition.
Test Solid State Relay inputs for appropriate
Control
signal from control.
Wiring Check for broken or improper wire connection.
Refer to “Ht:x” “Lo” may be followed by a “Ht:x” error.
Refer to “Ht:x” “Lo” may be followed by a “PnL” & “oFF” error.
Refer to “hT:Er” “Lo” may be followed by a “hT:Er” error.
Heat Loss Check for missing or damaged panels.
Identify correct Heater location and test
Element
continuity.
Fuse Test continuity of appropriate Fuse.
Ensure Solid State Relay switches ON / OFF
Solid State Relay at appropriate intervals. Test for closed or
open output condition.
Wiring Check for broken or improper wire connection.
Diagnostic Board Ensure board powers on.
Test Solid State Relay inputs for appropriate
Control
signal from control.
Current Sensor Measure continuity on Current Sensors.
Check harness connection between
Wiring
Diagnostic Board and Control Board.
Diagnostic Board Ensure board powers on.
Control Ensure board powers on.
Current Sensor Measure continuity on Current Sensors.
33
Service Manual for Flexible Batch Broiler Units
Symptom
Display shows “triP”
Display shows “Prob”
Cook Chain does not move /
Runs all the time
34
Cause Remedy
High Limit Test continuity on Thermostat located on
Thermostat Relay Heat Sink.
Ensure Cooling Fan runs when On / Off
Cooling Fan
Switch is turned ON.
Clean Cooling Fan and any other item which
Cooling
may not be allowing Relay Heat Sink to
obstruction
dissipate heat effectively.
Temperature Test continuity for open or shorted
Probe Temperature Probe.
Discharge Chute Discharge Chute is not properly in place.
Cook Chain is catching on another item, i.e.
Cook Chain
ash scraper, loader ramp, flame arrestor. May
obstruction
require adjustment of Ash Scraper Bracket.
It may be necessary to install shims behind or
Cook Chain not
underneath shaft bearings to ensure proper
properly adjusted
position and tension of the cook chain.
Deflection of Drive Chain should be
Loose Drive Chain
approximately 3/16”.
When tightening, ensure motor sprocket
Loose Motor
is orientated the same way as the shaft
Sprocket
sprocket.
Ensure Control is signaling to energize the
Control
Conveyor Motor Relay.
Ensure Conveyor Motor Relay is closing.
Solid State Relay Replace Solid State Relay if Conveyor Motor
runs non-stop.
Conveyor Motor Test Conveyor Motor for fault.
Capacitor Test Conveyor Motor Capacitor for fault.

PREVENTIVE MAINTENANCE
SEMIANNUAL
It is recommended to perform preventative
maintenance on the Broiler every 6 months. Over
time, dust and debris will accumulate, electrical
connections will loosen, and the following procedures
and inspections should be made to extend the life
of the components within the Broiler.
1. Vacuum dust and dirt from the cooling fan and
heat sink fins.
Service Manual for Flexible Batch Broiler Units
2. Perform a visual inspection of the Broiler, noting
and repairing any electrical connection which
appears damaged.
3. Check tightness of all electrical connections
throughout the Broiler. Pay particularly close
attention to all Element, Solid State Relay, and
Terminal Block connections as these will be
more affected over time.
4. Check tightness of electrical connections within
Plug and at receptacle
35
Service Manual for Flexible Batch Broiler Units

ELECTRICAL SCHEMATIC – FLEXIBLE BATCH BROILER

Heatsink
J1 6 WHT 51
Thermo Electric FBB, 208/240V~ 3P
1 YEL 50 WHT 51 Limit
12
*Shown with power ON & in normal operation mode
RED 71 177623C
PUR 70 BLK 41
BLK 28 1

1
+

YEL 50

L1
BLK 31

~
9 RED 52

ht 1
J1 & J2

SSR-1
3 RED 57 YEL 67
RED h1 RED 81
+ 3

T1
~
YEL 53
7
PUR 55 PUR 69 RED 26

2
5 RED 32 RED 42

L1
~
1
J2

GRN 73a +

SSR-2
8 BLU h2 BLU 82

ht 2
RED 57
RED 52
RED 71
ORN 59 YEL 66 + 2

T1
1

~
Controller PCB

3
CAVITY THERMOCOUPLE

BLK 56
4 PUR 68

L1
~

BLU 24
GRY 58
2

SSR-3
1
YEL61
BLU 54
YEL 64
YEL 73

YEL 62

3
6 YEL 65 ORN33 BLU 43

ht 3
T1
~
+ 2
GRN 73a BLK h3 BLK 83
+ 3

L1

BLK 29
-
101
1

SSR-4
102 ORN 73
2 BRN 37 BRN 47

T1
+
1

4
103
3

ht 4
BLK 74 +

RED 27
4
104 2

L1
~
RED 87
3
SSR-5

YEL 62 BLU 35
T1
~

5
RED 74 ORN 45
RED 75 BLK 75 1
BLU 85
L1
~

BLU 25

ht 5
2
SSR-6

YEL 61 + 3

RED h4
BLU h5
WHT 36
T1
~
RED 72
YEL 73
BLU 54
ORN 60

TERMINAL
ELEMENT
BLK

6
ORN 59
GRY 58

101 #1 1 WHT 46 + 1
BLOCK
1
Current PCB

BLK

ht 6
2 1 102 2
2 RED 2

BLK h3
Conveyor Motor

103 3 BLK 86
2 1 #2 4 RED
+

3 3
- + 104
4

BLK h6
3 2 1

4b
BLU

BLU

Conveyor BLU
L1

RED h1
SSR
#3 2 1

ht 4b
YEL 44
Light
Load

3 2 1 1 BLU

BLU h2
L1 T1
L1

24V~ Sec. 2
XFMR

RED 84
BRN

BLK
ORN

3
L1

Primary

RED h4b
L2

BLK
BLK

BLK

BLK
L2
4µF
Cap.

L2

2 1
Heatsink
BLK 28

2 1 Fan
L3
RED 26
RED 12
YEL 13
N.O.

Com

N.C.
K2

BLU h5
(TOP)

L3
YEL 15

YEL 24
RED 14

RED 23

BLU 24
RED 75
L3

BLK 77
YEL 17

RED 18
CT2
COIL
(BOTTOM)

NO

Com

NC
K1

RED 20

BRN 22 BRN 22 Controls Side

RED 74
BLU 76

ht1,2 & 3 = 3300W

Rear View - Element Location

ORN 21 ORN 21
1a

2a

3a
BLK

BLU
RED

ht6

ht3
CT1
COIL

BLK 77
YEL 19
with K1 & K2 in normal operation mode.
*Properly instaled interlocked panels shown

ht4,5 & 6 = 3800W

BLU
ht5
Side Panel Magnet

BLU 76

N.C.
ht2

4 4 BLK 9
Element
Heating
Typical

WHT
3 3
N.O. BLK 2 2
ht4b

BRN 1 1
BLU 8A
N.O.
RED 10
YEL 11

ht4

ht1

10A
BLU 8

ht4b = 2200W

BREAKER
Side Safety Interlock
BLK 1
RED 2
BLU 3
BLK 76A
WHT 77A
YEL 64

BLU
Rear Panel Magnet

N.C.
208/240V~ 3P
LINE SUPPLY
TERMINAL

4 4
MAINS
BLOCK

WHT 3 3
N.O. BLK 2 2
Power
Switch

BRN 1 1
N.O.
L1
L2
L3

Rear Safety Interlock

36
 Service Manual for Flexible Batch Broiler Units

NOTES

37
Service Manual for Flexible Batch Broiler Units

NOTES

38
 Service Manual for Flexible Batch Broiler Units

CUSTOMER ASSISTANCE
To aid in reporting this unit in case of loss or theft, please record below the model number and serial number
located on the unit. We also suggest you record all the information listed and retain for future reference.

MODEL NUMBER_________________________ SERIAL NUMBER_ _______________________

DATE OF PURCHASE_____________________________________________________________

DEALER_________________________________ TELEPHONE_ ___________________________

SERVICER_______________________________ TELEPHONE_ ___________________________

NORTH AMERICA & LATIN AMERICA CONTINENTAL EUROPE

Duke Manufacturing Company EU Headquarter Office

2305 N. Broadway Duke Manufacturing
St. Louis, MO 63102 CR s.r.o. Vitavska 219,
Phone: 314-231-1130 Stechovice 25207
Toll Free: 1-800-735-3853 Phone: +420 257-741-033
Fax: 314-231-5074

UK & IRELAND ASIA

Duke Mfg UK Asia Office

Duke House Duke Food Service Equipment
Unit 10, Greendale Business Park (shanghai) Company Limited
Woodbury Salterton 1F, Building #17-2,
Exeter 658 Nong Jin Zhong Road
Devon - UK EX5 1EW Shanghai, China 200335
Tel: 01395 234140 Tel: +86 21 6876 9272
FAX: 01395 234154 Fax: +86 21 33600628

TO ACCESS INTERNET: www.dukemfg.com

Please provide the following information when you write or call: model number, serial number, date of
purchase, your complete mailing address (including zip code), and description of the problem.

39
Service Manual for Flexible Batch Broiler Units

Duke Manufacturing Co.

2305 N. Broadway
St. Louis, MO 63102
Phone: 314-231-1130
Toll Free: 1-800-735-3853
Fax: 314-231-5074
www.dukemfg.com

EU Headquarter Office
Duke Manufacturing C.R. s.r.o.
Prologis Park D1 West, Building 4
Zdebradska 92
Ricany-Jazlovice, 251 01
Czech Republic
Phone: 42 (0) 257-741-033
Fax: 42 (0) 257-741-039

Duke Mfg UK
Duke House
Unit 10, Greendale Business Park
Woodbury Salterton
Exeter
Devon - UK EX5 1EW
Tel: +44 (0) 1395 234140
FAX: +44 (0) 1395 234154

Asia Office
Duke Food Service Equipment (shanghai) Company Limited
1F, Building #17-2, 658 Nong Jin Zhong Road
Shanghai, China 200335
Tel: +86 21 6876 9272
Fax: +86 21 33600628

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